U.S. patent application number 13/031709 was filed with the patent office on 2012-04-12 for coating, article coated with coating, and method for manufacturing article.
This patent application is currently assigned to HON HAI PRECISION INDUSTRY CO., LTD.. Invention is credited to HSIN-PEI CHANG, CHENG-SHI CHEN, WEN-RONG CHEN, HUANN-WU CHIANG, CHUANG MA.
Application Number | 20120088083 13/031709 |
Document ID | / |
Family ID | 45841833 |
Filed Date | 2012-04-12 |
United States Patent
Application |
20120088083 |
Kind Code |
A1 |
CHANG; HSIN-PEI ; et
al. |
April 12, 2012 |
COATING, ARTICLE COATED WITH COATING, AND METHOD FOR MANUFACTURING
ARTICLE
Abstract
A coating includes a nano-composite layer including a plurality
of stacked films. Each film includes a zirconium nitride layer and
a zirconium yttrium nitride layer.
Inventors: |
CHANG; HSIN-PEI; (Tu-Cheng,
TW) ; CHEN; WEN-RONG; (Tu-Cheng, TW) ; CHIANG;
HUANN-WU; (Tu-Cheng, TW) ; CHEN; CHENG-SHI;
(Tu-Cheng, TW) ; MA; CHUANG; (Shenzhen,
CN) |
Assignee: |
HON HAI PRECISION INDUSTRY CO.,
LTD.
Tu-Cheng
TW
HONG FU JIN PRECISION INDUSTRY (ShenZhen) Co., LTD
Shenzhen City
CN
|
Family ID: |
45841833 |
Appl. No.: |
13/031709 |
Filed: |
February 22, 2011 |
Current U.S.
Class: |
428/216 ;
204/192.15; 428/212; 428/457; 428/698 |
Current CPC
Class: |
Y10T 428/24975 20150115;
C23C 28/04 20130101; C23C 28/42 20130101; Y10T 428/24942 20150115;
Y10T 428/31678 20150401; C23C 28/044 20130101; C23C 28/40
20130101 |
Class at
Publication: |
428/216 ;
428/698; 428/457; 428/212; 204/192.15 |
International
Class: |
B32B 7/02 20060101
B32B007/02; C23C 14/06 20060101 C23C014/06; C23C 14/35 20060101
C23C014/35; B32B 9/00 20060101 B32B009/00; B32B 15/04 20060101
B32B015/04 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 6, 2010 |
CN |
201010299025.8 |
Claims
1. A coating, comprising: a nano-composite layer comprising an
equal number of alternating zirconium nitride layers and zirconium
yttrium nitride layers; wherein the number of the zirconium nitride
layers is about 20.about.50.
2. (canceled)
3. The coating as claimed in claim 1, wherein each zirconium
nitride layer has a thickness of about 10 nanometers to about 20
nanometers.
4. The coating as claimed in claim 1, wherein each zirconium
yttrium nitride layer has a thickness of about 10 nanometers to
about 20 nanometers.
5. The coating as claimed in claim 1, wherein the coating has a
thickness of about 1 micrometer to about 4 micrometers.
6. The coating as claimed in claim 1, wherein the coating further
comprises a color layer covering on the nano-composite layer, to
decorate the appearance of the coating.
7. An article, comprising: a substrate; a bonding layer deposited
on the substrate; and a coating deposited on the bonding layer, the
coating including a nano-composite layer, the nano-composite layer
comprising an equal number of alternating zirconium nitride layers
and zirconium yttrium nitride layers; wherein the number of the
zirconium nitride layers is about 20.about.50.
8. (canceled)
9. The article as claimed in claim 7, wherein each zirconium
nitride layer has a thickness of about 10 nanometers to about 20
nanometers.
10. The article as claimed in claim 7, wherein each zirconium
yttrium nitride layer has a thickness of about 10 nanometers to
about 20 nanometers.
11. The article as claimed in claim 7, wherein the coating has a
thickness of about 1 micrometer to about 4 micrometers.
12. The article as claimed in claim 7, further comprising a color
layer covering on the nano-composite layer.
13. The article as claimed in claim 7, wherein the substrate is
made of high speed steel, hard alloy, or stainless steel.
14. The article as claimed in claim 7, wherein the bonding layer is
a zirconium yttrium layer, the bonding layer has a thickness of
about 0.05 micrometers to about 0.2 micrometers
15. The article as claimed in claim 7, wherein the chemical
stability of the bonding layer is between the chemical stability of
the substrate and the chemical stability of the coating, and the
coefficient of thermal expansion of the bonding layer is between
the coefficient of thermal expansion of the substrate and the
coefficient of thermal expansion of the coating.
16. The article as claimed in claim 7, wherein the coating contacts
the bonding layer via one of the zirconium nitride layers.
17.-20. (canceled)
21. A coating, comprising: a nano-composite layer comprising a
plurality of stacked films, wherein each film includes a zirconium
nitride layer and a zirconium yttrium nitride layer, a number of
the films is about 20.about.50.
22. The coating as claimed in claim 21, wherein each zirconium
nitride layer has a thickness of about 10 nanometers to about 20
nanometers.
23. The coating as claimed in claim 21, wherein each zirconium
yttrium nitride layer has a thickness of about 10 nanometers to
about 20 nanometers.
24. The coating as claimed in claim 21, wherein the coating has a
thickness of about 1 micrometer to about 4 micrometers.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] The exemplary disclosure generally relates to coatings, and
particularly relates to articles coated with the coatings and a
method for manufacturing the articles.
[0003] 2. Description of Related Art
[0004] Physical vapor deposition (PVD) has conventionally been used
to form a coating on metal bases of cutting tools or molds.
Materials used as this coating material are required to have
excellent durability. At present, Titanium nitride (TiN) and
Titanium-aluminum nitride (TiAlN) are mainly used as a material
satisfying these requirements. However, these coating materials
have a poor adhesion to metal bases and may be easily peeled
off.
[0005] Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Many aspects of the embodiments can be better understood
with reference to the following drawings. The components in the
drawings are not necessarily drawn to scale, the emphasis instead
being placed upon clearly illustrating the principles of the
exemplary coating, article coated with the coating and method for
manufacturing the article. Moreover, in the drawings like reference
numerals designate corresponding parts throughout the several
views. Wherever possible, the same reference numbers are used
throughout the drawings to refer to the same or like elements of an
embodiment.
[0007] FIG. 1 is a cross-sectional view of an exemplary embodiment
of a coating.
[0008] FIG. 2 is a cross-sectional view of an article coated with
the coating in FIG. 1.
[0009] FIG. 3 is a schematic view of a magnetron sputtering coating
machine for manufacturing the article in FIG. 2.
DETAILED DESCRIPTION
[0010] Referring to FIG. 1, a coating 30 includes a nano-composite
layer 31, which comprises a plurality of stacked films 311. Each
film 311 includes a zirconium nitride (ZrN) layer 311 and a
zirconium yttrium nitride (ZrYN) layer 313. In other words, the
nano-composite layer 31 includes an equal number of alternating ZrN
layers 311 and ZrYN layers 313. The ZrN layers 311 and the ZrYN
layers 313 may be deposited by magnetron sputtering.
[0011] In this exemplary embodiment, the number of the films 311 is
about 20.about.50. Each ZrN layer 311 has a thickness of about 10
nanometers to about 20 nanometers. Each ZrYN layer 313 has a
thickness of about 10 nanometers to about 20 nanometers. The
coating 30 has a thickness of about 1 micrometer to about 4
micrometers. The coating 30 may also include a color layer 33
covering the nano-composite layer 31, to decorate the coating
30.
[0012] Referring to FIG. 2, an exemplary article 40 includes a
substrate 10, a bonding layer 20 deposited on the substrate 10 and
the coating 30 deposited on the bonding layer 20. The substrate 10
may be made of metal, such as high speed steel, hard alloy, or
stainless steel. The article 40 may be a cutting tool, a mold, or a
housing for an electronic device. The bonding layer 20 is a
zirconium yttrium (ZrY) layer. The bonding layer 20 has a thickness
of about 0.05 micrometers to about 0.2 micrometers, and in this
exemplary embodiment has a thickness of 0.1 micrometer. The bonding
layer 20 can be deposited by magnetron sputtering. The chemical
stability of the bonding layer 20 is between the chemical stability
of the substrate 10 and the chemical stability of the coating 30,
and the coefficient of thermal expansion of the bonding layer 20 is
between the coefficient of thermal expansion of the substrate 10
and the coefficient of thermal expansion of the coating 30. Thus,
the bonding layer 20 improves the binding force between the
substrate 10 and the coating 30 so the coating 30 can be firmly
deposited on the substrate 10. The coating 30 contacts with the
bonding layer 20 via ZrN layer 311.
[0013] Referring to FIG. 3, a method for manufacturing the article
40 may include at least the following steps.
[0014] Providing a substrate 10. The substrate 10 may be made of
high speed steel, hard alloy, or stainless steel.
[0015] Pretreating the substrate 10 by washing with a solution
(e.g., alcohol or acetone) in an ultrasonic cleaner, to remove,
e.g., grease, dirt, and/or impurities, then drying the substrate
10. Then the substrate 10 is cleaned by argon plasma cleaning. The
substrate 10 is retained on a rotating bracket 50 in a vacuum
chamber 60 of a magnetron sputtering coating machine 100. The
vacuum level of the vacuum chamber 60 is set to about
8.0.times.10.sup.-3 Pa. Argon is floated into the vacuum chamber 60
at a flux of about 300 standard cubic centimeters per minute (sccm)
to 600 sccm from a gas inlet 90. Then a bias voltage is applied to
the substrate 10 in a range of about -300 volts to -800 volts for
about 3-10 minutes. Thereby, the substrate 10 is washed by argon
plasma, to further remove any grease or dirt. Thus, the binding
force between the substrate 10 and the bonding layer 20 is
enhanced.
[0016] In depositing a bonding layer 20 on the substrate 10, the
temperature in the vacuum chamber 60 is set to between about 150
degrees Celsius (.degree. C.) and about 300.degree. C. Argon is
floated into the vacuum chamber 60 at a flux of about 150 sccm to
300 sccm from the gas inlet 90. In this exemplary embodiment the
flux is about 150 sccm. The substrate 10 is rotated at about 1.0
revolution per minute (rpm) to 3 rpm. A power source applied to a
zirconium yttrium alloy target 70 and a zirconium target 80 may
both be in a range of about 20 amperes (A) to about 100 A. A bias
voltage applied to the substrate 10 may be in a range of about -100
volts to -300 volts for about 5 min to about 15 min, to deposit the
bonding layer 20 on the substrate 10. The zirconium yttrium alloy
target contains atomic zirconium in a range about 70 to about 90 wt
%.
[0017] In depositing the nano-composite layer 31 on the bonding
layer 20, nitrogen is floated into the vacuum chamber 60 at a flux
of about 10 sccm to about 200 sccm and argon is floated into the
vacuum chamber 60 at a flux of about 150 sccm to 300 sccm from the
gas inlet 90. The zirconium yttrium alloy target 70 and the
zirconium target 80 in the vacuum chamber 60 are alternatively
evaporated for about 60 min to about 120 min, to alternatively
deposit an equal number of alternating ZrN layers 311 and ZrYN
layers 313 on the bonding layer 20.
[0018] The color layer 33 may be deposited on the nano-composite
base 31 to improve the appearance of the article 40.
[0019] During depositing the ZrYN layers 313, atomic yttrium can
react with atomic zirconium to form solid solution alloy. Atomic
yttrium cannot react with atomic nitrogen but can react with atomic
zirconium to form zirconium-nitrogen crystals. Atomic yttrium is
independently located at the boundary of the zirconium-nitrogen
crystals, which can prevent the zirconium-nitrogen crystals from
enlarging, to maintain the zirconium-nitrogen crystals at a
nanometer level. The nanometer level zirconium-nitrogen crystals
can improve durability of the coating 30.
[0020] It is to be understood, however, that even through numerous
characteristics and advantages of the exemplary disclosure have
been set forth in the foregoing description, together with details
of the system and function of the disclosure, the disclosure is
illustrative only, and changes may be made in detail, especially in
matters of shape, size, and arrangement of parts within the
principles of the disclosure to the full extent indicated by the
broad general meaning of the terms in which the appended claims are
expressed.
* * * * *